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Energy efficiency is a critical requirement while operating machine tools. Currently, efficiency is one of the key factors considered during installation of motors. Measures taken to improve efficiency include adequate lubrication, proper work management, servicing and maintenance and management of back EMF Efficient utilization of energy is important across all sectors of industry and economy. Machine tools comprise machines such as the lathe machine, the drill and sheet metal cutting and bending machines. Energy utilization varies as the work of the machine progresses. In milling and drilling operation the spindle or the cutting tool requires much more energy as the volume of metal being removed increases and subsequently decreases as the bit approaches the end of the cutting.
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Critical Need for Energy Saving In Machining The overriding importance of energy efficiency and saving is the overall cost reduction of power requirements. All measures that can reduce the current drawn by a machine, end up reducing the power consumption of the machine. Currently, lathe and drills machines with geared motors specify the energy efficiency as a marketing strategy.
General Measures for Energy Conservation in the Workshop Good management of the operation is important for energy efficiency. Gradual removal of material is more preferred than the sudden removal of huge volume of metal. This is because it exacts more stress to the machine than the gradual process. Operator support during work increases efficiency by reducing time spent in moving the base load.
Energy Demand during Drilling and Milling Various operating components consume energy during operation. In lathe operation, processing of the cooling liquid, motor and gears operation, spindle movement and the logical control units consume power differently. The greatest consumer however is during machining. Measures such as efficient lubrication, cooling and accuracy during operation must be observed to save on energy.
Efficiency of Drive Components The efficiency of the spindle of the lathe machine is largely influenced by the ratio of the power consumed versus that of power delivered. Drive modules, motors, gears and mechanical components convert the electrical power to mechanical power. Losses occurring due to frictional losses, poor calibration and wear and tear increase the cost of operation.
The Introduction of Regenerative Supply Components The requirement of a braking system is very crucial in every machine system. When the machine is switched off, all moving parts have a momentum which must be managed because all that mechanical energy is converted to electrical energy. Power efficient machines must have a system to allow for the back EMF to avoid damage to the electrical components.
Power Consumption in Lathe Machine and sheet metal bending operation Main energy consuming processes are the rotation and the circulation of the coolant. With the sheet metal bending machine, the folding process is the heaviest energy consumer. The firmness of the cutting tool and the accuracy has great bearing on the power requirements on the drive motor hence the efficiency.
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